Page 1 WaveRunner GP1300R SUPPLEMENTARY SERVICE MANUAL *LIT186160290* LIT-18616-02-90 F1G-28197-1G-1X...
Page 2 GP1300R SERVICE MANUAL: F1G-28197-1F-11 (LIT-18616-02-44) A10001-0* WaveRunner GP1300R SUPPLEMENTARY SERVICE MANUAL ©2004 by Yamaha Motor Corporation, USA 1st Edition, October 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited.
Page 3 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
Page 4 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
Page 5 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
Page 6 Symbols F to H in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 2-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease...
Page 7: General Information
INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE ANALYSIS TRBL ANLS...
Page 8: Table Of Contents
GENERAL INFORMATION IDENTIFICATION NUMBERS ................1 PRIMARY l.D. NUMBER ................1 ENGINE SERIAL NUMBER ................. 1 JET PUMP UNIT SERIAL NUMBER ............1 HULL IDENTIFICATION NUMBER (H.l.N.)..........1 SPECIAL SERVICE TOOLS ................2 REMOVAL AND INSTALLATION..............3 SPECIFICATIONS GENERAL SPECIFICATIONS ................4 MAINTENANCE SPECIFICATIONS ..............
Page 9 JET PUMP UNIT IMPELLER DUCT AND IMPELLER HOUSING 1 ..........27 EXPLODED DIAGRAM ................27 REMOVAL AND INSTALLATION CHART ..........27 IMPELLER DUCT AND DRIVE SHAFT ............29 EXPLODED DIAGRAM ................29 REMOVAL AND INSTALLATION CHART ..........29 SERVICE POINTS ..................31 Drive shaft removal ................
Page 10 TROUBLE ANALYSIS TROUBLE ANALYSIS..................48 SELF-DIAGNOSIS ..................48 WIRING DIAGRAM...
Page 11: Identification Numbers
IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label 1 attached inside the engine compartment. Starting primary l.D. number: F1G: 809601 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit.
Page 12: Special Service Tools
SPECIAL SERVICE TOOLS INFO SPECIAL SERVICE TOOLS Using the special service tools recommended by Yamaha will aid service and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For USA and Canada, use the special ser- vice tools starting with part numbers “J-,”...
Page 13: Removal And Installation
SPECIAL SERVICE TOOLS INFO REMOVAL AND INSTALLATION 1 Drive shaft holder (impeller) YB-06151 YB-06096 90890-06519 YB-06151 Drive shaft holder 5 (impeller) 90890-06519 2 Slide hammer and adapters (jet pump bearing) YB-06096 3 Stopper guide plate (jet pump bearing) 90890-06501 90890-06535 90890-06501 4 Bearing puller assembly (jet pump bearing)
Page 14: General Specifications
SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit GP1300R Model code Hull Engine/jet Dimensions Length mm (in) 2,930 (115.4) Width mm (in) 1,150 (45.3) Height mm (in) 1,020 (40.2) Dry weight kg (lb) 297 (655) Maximum capacity Person/kg (lb) 2/160 (353) Performance Maximum output kW (PS) at r/min...
Page 15 Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 Research Octane Number YAMALUBE 2-W has been developed for this watercraft and it is available at a Yamaha dealer. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter...
Page 16: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit GP1300R Cylinder head Warpage limit mm (in) 0.10 (0.004) Minimum compression 640 (6.4, 91) pressure (kgf/cm , psi) Cylinders Bore size mm (in) 84.000–84.018 (3.3071–3.3078) Taper limit mm (in) 0.080 (0.0032) Out-of-round limit mm (in) 0.050 (0.0020)
Page 17: Jet Pump Unit
SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Crankshaft assembly Crank width A mm (in) 72.95–73.00 (2.872–2.874) Deflection limit B mm (in) 0.05 (0.002) Deflection limit C mm (in) 0.15 (0.006) Big end side clearance D mm (in) 0.250–0.750 (0.0098–0.0295) Maximum small end axial mm (in) 2.000 (0.0787) play E...
Page 18: Hull And Hood
SPEC MAINTENANCE SPECIFICATIONS HULL AND HOOD Model Item Unit GP1300R Free play Throttle lever free play mm (in) 4–7 (0.16–0.28) ELECTRICAL Model Item Unit GP1300R Battery Type Fluid Voltage, capacity V, Ah 12, 19 Specific gravity 1.27 ECM unit (B/R – Ground for cylinder #1) (B/W –...
Page 19 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Ignition coil Minimum spark gap mm (in) 10–11 (0.39–0.43) Ω Primary coil resistance 0.26–0.36 (B/W – body) Secondary coil resistance kΩ 3.5–4.7 (B/W – spark plug lead terminal) Spark plug lead resistance kΩ 6.1–14.3 kΩ...
Page 20 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Speed sensor Output voltage (on pulse) 11.6 Output pulse/one full turn Throttle position sensor Output voltage (P – B/O) at trolling speed 0.793–0.807 Fuel sender Fuel sender resistance Ω Position A 133.5–136.5 Ω Position B 5–7 Fuel injector...
Page 21: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Fuel system Strap/fuel tank/oil tank Bolt Oil filler hose screw clamp — — 0.06 0.32 Retainer/fuel pump module —...
Page 22 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Muffler stay Bolt Cover/catalytic converter Bolt housing/catalytic converter Mixing joint Bolt Exhaust chamber assembly Bolt Exhaust chamber stay/ Bolt exhaust chamber assembly Exhaust chamber joint Bolt Coupling cover...
Page 23 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Cable holder Bolt Pickup coil Bolt 0.49 Lighting coil Bolt Drive Drive coupling — coupling Flywheel magneto Bolt Starter motor/negative Bolt battery lead Starter motor Bolt Mount bracket...
Page 24 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Handlebar switch assembly Screw 0.34 QSTS grip assembly Screw 0.34 Grip end Bolt 0.12 QSTS cable housing Screw 0.34 Plate/steering column assembly Steering column assembly Steering arm Steering sensor...
Page 25 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Sponson Bolt Spout 0.54 Rope hole 0.54 Bow eye Bolt Flap Bolt 0.76 Drain plug/packing — Engine mount Bolt Engine damper Bolt 0.64 Electrical Tapping...
Page 26: General Torque
SPEC TIGHTENING TORQUES GENERAL TORQUE General torque This chart specifies tightening torques for stan- Nut A Bolt B specifications dard fasteners with a standard ISO thread N•m kgf•m ft•lb pitch. Tightening torque specifications for spe- 8 mm cial components or assemblies are provided in 10 mm applicable sections of this manual.
Page 27: Cable And Hose Routing
SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING È É Ê Í Î Ë Ì Ì 1 Fuel tank breather hose 9 Exhaust temperature sensor E Cooling water outlet hose 2 Cooling water pilot outlet F Wire harness lead 3 Throttle cable 0 Negative battery lead G Electrical bilge pump lead...
Page 28 SPEC CABLE AND HOSE ROUTING È É Ê Í Î Ë Ì Ì È Align the parting line on the fuel filler neck with the lot mark on the fuel filler hose. É To wire harness Ê To ventilation socket Ë...
Page 29 SPEC CABLE AND HOSE ROUTING È É Ê Ì Ë N Î Í 1 Buzzer lead A Speed sensor coupler J Sensor assembly (intake air 2 Throttle cable B Oil level sensor coupler temperature and atmospheric 3 Positive battery lead C Buzzer coupler pressure) 4 Battery breather hose...
Page 30 SPEC CABLE AND HOSE ROUTING È É Ê Ì Ë N Î Í È To cylinder #3 É To cylinder #2 Ê To cylinder #1 Ë Cooling water temperature sensor Ì Exhaust temperature sensor Í To positive battery terminal Î To starter motor...
Page 31 SPEC CABLE AND HOSE ROUTING È 1 Bilge hose 1 A Electrical bilge pump lead 2 Bilge hose 2 3 Steering cable È Contact the corrugated tube (bilge hose 1) to 4 Bilge hose 3 the hose screw clamp. 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose (cooling water inlet) 8 Flushing hose...
Page 32 SPEC CABLE AND HOSE ROUTING Ê È É Ë Ò Ì Ñ Í Ð Ï Î 1 Oil delivery hose #1 Ê Fasten the sub-wire harness with the plastic tie 2 Sub-wire harness on the rib of the fuel rail. Be sure to position the 3 Oil delivery hose #3 plastic tie so that the fastener is visible from the 4 Oil delivery hose #2...
Page 33 SPEC CABLE AND HOSE ROUTING Ê È É Ë Ò Ì Ñ Í Ð Ï Î Î Push the corrugated tube toward the oil pump, and then tape it. Ï To oil tank Ð To check valve Ñ Install the oil hoses into the hose holders so that the holders do not cover the check valve clips.
Page 34 SPEC CABLE AND HOSE ROUTING Ð Ê Ë É È Ì Ñ Í Ï Î Ï Î Õ Ô Ò Ó Ö Ï Ú Ù Ø Û × 15˚ 15˚ Ï 20˚ 1 Cooling water hose Ë To cooling water pilot outlet on starboard side Ì...
Page 35 SPEC CABLE AND HOSE ROUTING Ð Ê Ë É È Ì Ñ Í Ï Î Ï Î Õ Ô Ò Ó Ö Ï Ú Ù Ø Û × 15˚ 15˚ Ï 20˚ Ð Contact the corrugated tube to the hose screw Ø...
Page 36: Maintenance Interval Chart
INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART The following chart gives general guidelines for periodic maintenance. However, depending on your operating conditions maintenance may need to be performed more frequently. MAINTENANCE INTERVAL INITIAL THEREAFTER EVERY 10 hours 50 hours 100 hours 100 hours 200 hours ITEM 6 months 12 months 12 months 24 months Spark plug...
Page 37: Exploded Diagram
IMPELLER DUCT AND IMPELLER HOUSING 1 PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND IMPELLER Follow the left “Step” for removal. HOUSING 1 REMOVAL Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING”...
Page 38: Exploded Diagram
IMPELLER DUCT AND IMPELLER HOUSING 1 PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Water inlet cover Seal Water inlet strainer Seal Reverse the removal steps for installation.
Page 39 IMPELLER DUCT AND DRIVE SHAFT PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly. SHAFT DISASSEMBLY Impeller Left-hand threads Spacer Bolt/washer O-ring Not reusable Washer...
Page 40 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive shaft Rear bearing Not reusable Spacer Front bearing Not reusable Oil seal Not reusable Oil seal Not reusable Impeller duct Reverse the disassembly steps for assembly.
Page 41: Service Points
IMPELLER DUCT AND DRIVE SHAFT PUMP SERVICE POINTS Drive shaft removal 1. Remove: • Impeller Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: • Nut 1 Drive shaft holder: YB-06151 Drive shaft holder 5:...
Page 42 IMPELLER DUCT AND DRIVE SHAFT PUMP 4. Remove: È • Rear bearing Slide hammer and adapters: YB-06096 Stopper guide plate: 90890-06501 Bearing puller assembly: 90890-06535 Stopper guide stand: 90890-06538 É È For USA and Canada É For worldwide 5. Remove: •...
Page 43: Impeller Inspection
IMPELLER DUCT AND DRIVE SHAFT PUMP 6. Remove: • Oil seal Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Drive shaft needle bearing installer: YB-06196 Needle bearing attachment: 90890-06614 NOTE: Remove the oil seals with press. Impeller inspection Refer to “JET PUMP UNIT” in Chapter 3 in the base manual.
Page 44 IMPELLER DUCT AND DRIVE SHAFT PUMP 2. Install: • Front bearing NOTE: • Install the front bearing and drive shaft with a press. • Press the front bearing with a pipe that is more than 85 mm (3.35 in) long, and which has an inner diameter of 25 mm (0.98 in).
Page 45 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Install: • Rear bearing Drive shaft needle bearing depth stop: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impel- ler duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 46 mm (1.81 in) and an inner diameter of 20 mm (0.79 in).
Page 46: Electrical Components
– ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Slant detection switch 0 Stepping motor J Lighting coil and pickup coil 2 Fuel pump A Rectifier/regulator K Engine stop switch, engine 3 Sensor assembly (intake air B Electric bilge pump shut-off switch, and start C Speed sensor temperature and atmospheric switch...
Page 47: Ignition System
– ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 19 : 20 : 24 : 25 : 26 : 27 : 5 6 7 8 10 11 12 13 15 16 17 18 10 : 28 : 11 : 30 : 12 : 31 : 13 :...
Page 48 – ELEC IGNITION SYSTEM WIRING DIAGRAM 19 : 20 : 24 : 25 : 26 : 27 : 5 6 7 8 10 11 12 13 15 16 17 18 10 : 28 : 11 : 30 : 12 : 31 : 13 : 32 :...
Page 49: Sensor Assembly
Checking steps: • Measure the ambient temperature. • Connect a computer to the watercraft and use the Yamaha Diagnostic System to display the intake air temperature. • If the ambient temperature and the dis- played intake air temperature differ by more than ±...
Page 50: Off Throttle Steering System
– ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 15 : 16 : 17 : 10 : 18 : 11 : 24 : 12 : 26 : 5 6 7 8 10 11 12 13 15 16 17 18 13 : 28 : R/Y R/Y...
Page 51: Steering Sensor
100 N (10 kgf, 22 lb). • Check that the following is displayed in the “Engine Monitor” window of the Yamaha Diagnostic System. When handlebar When handlebar pulled not pulled •...
Page 52: Steering Column
HULL STEERING COLUMN HOOD STEERING COLUMN EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING COLUMN REMOVAL Follow the left “Step” for removal. Steering console cover assembly Refer to “STEERING CONSOLE COVER”...
Page 53: Exploded Diagram
HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) Step Procedure/Part name Q’ty Service points Plate Rivet Reverse the removal steps for installation.
Page 54: Removal And Installation Chart
HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) 16 N • m (1.6 kgf • m, 11 ft • Ib) 8 × 60 mm 16 N • m (1.6 kgf • m, 11 ft • Ib) 5.0 N •...
Page 55 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) 16 N • m (1.6 kgf • m, 11 ft • Ib) 8 × 60 mm 16 N • m (1.6 kgf • m, 11 ft • Ib) 5.0 N •...
Page 56: Service Points
HULL STEERING COLUMN HOOD SERVICE POINTS Steering column assembly 1. Install: • Spacer 1 • Bolt 2 • Bolt 3 • Steering sensor 4 • Nut 5 NOTE: Tighten the nut while pushing the steering sen- sor against the spacer. Nut: 16 N •...
Page 57: Exhaust System
HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM SERVICE POINTS Exhaust component parts assembly 1. Install: • Exhaust outlet • Rubber hose • Water tank NOTE: • Insert the exhaust outlet 45–50 mm (1.77– 1.97 in) a into the rubber hose. • Make sure that there is a distance of 10 mm (0.39 in) b between the parting lines of the exhaust outlet and the rubber hose.
Page 58 Stepping motor stuck open Stepping motor stuck closed If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How-...
Page 59 GP1300R È R/Y R/Y B B B Pu/Y Pu/B Pu/R 10 11 W W/L B/Y B/G B/O B/L W/L O W/Y 12 13 14 15 16 17 18 19 20 21 L/R G/B G/R G G/Y B/R O Pu/Y Pu/B 23 24 25 26 27 28 29 30 31 32 Pu/R R/Y L/B B P/G P W/B B B/Y B/W B/O B/L...
Page 60 WIRING DIAGRAM GP1300R 1 ECM Color code 2 Sensor assembly (intake air temperature and : Black atmospheric pressure) : Brown 3 Spark plugs : Green 4 Ignition coils : Gray 5 Fuse (20 A) : Blue 6 Fuses (3 A) : Orange 7 Main and fuel pump relay : Pink...
Page 61 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Dec. 2004 –...
Page 62 WaveRunner GP1300R SERVICE MANUAL *LIT186160244* LIT-18616-02-44 F1G-28197-1F-11...
Page 63 NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
Page 64 HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
Page 65 IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
Page 66 HOW TO USE THIS MANUAL 1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 2 Numbers are given in the order of the jobs in the exploded diagram. 3 Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
Page 67 Symbols F to H in an exploded diagram indi- cate the grade of lubricant and the lubrication point. F Apply Yamaha 2-stroke motor oil G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide grease...
Page 68 INDEX A30000-0 GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT INSP FUEL SYSTEM FUEL POWER UNIT POWR JET PUMP UNIT PUMP – ELECTRICAL SYSTEM ELEC HULL AND HOOD HULL HOOD TROUBLE ANALYSIS TRBL ANLS...
Page 69 INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION NUMBERS ................. 1-1 PRIMARY l.D. NUMBER ................1-1 ENGINE SERIAL NUMBER ..............1-1 JET PUMP UNIT SERIAL NUMBER ............1-1 HULL IDENTIFICATION NUMBER (H.l.N.)..........1-1 SAFETY WHILE WORKING..............1-2 FIRE PREVENTION .................. 1-2 VENTILATION ................... 1-2 SELF-PROTECTION.................
Page 70: Identification Numbers
IDENTIFICATION NUMBERS INFO A60700-0* IDENTIFICATION NUMBERS PRIMARY l.D. NUMBER The primary l.D. number is stamped on a label 1 attached inside the engine compartment. Starting primary l.D. number: F1G: 800301 ENGINE SERIAL NUMBER The engine serial number is stamped on a label 1 attached to the engine unit.
Page 71: Safety While Working
Protect your hands and feet by wearing protec- tive gloves or safety shoes when necessary. PARTS, LUBRICANTS, AND SEALANTS Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the watercraft.
Page 72: Good Working Practices
SAFETY WHILE WORKING INFO Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene.
Page 73: Disassembly And Assembly
SAFETY WHILE WORKING INFO 3. Non-reusable parts Always use new gaskets, seals, O-rings, oil seals, cotter pins, circlips, etc., when installing or assembling parts. DISASSEMBLY AND ASSEMBLY 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts during assembly.
Page 74: Special Service Tools
SPECIAL SERVICE TOOLS INFO SPECIAL SERVICE TOOLS Using the special service tools recommended by Yamaha will aid service and enable accu- rate assembly and tune-up. Improvisations and using improper tools can damage the equipment. NOTE: • For USA and Canada, use the special ser- vice tools starting with part numbers “J-,”...
Page 75 F Test harness (6 pins) YB-06849 Test harness SM6195021-6 (6 pins) 90890-06849 G Lower unit pressure/vacuum tester YB-06848 YB-06849 90890-06848 90890-06849 YB-35956-A Vacuum/pressure pump gauge set 90890-06756 H Yamaha diagnostic system (CD-ROM only) 60V-WS853-01 YB-35956-A 90890-06756 60V-WS853-01 YAMAHA DIAGNOSTIC SYSTEM INSTALLATION MANUAL 60V-2819K-10...
Page 76: Removal And Installation
SPECIAL SERVICE TOOLS INFO REMOVAL AND INSTALLATION 1 Coupler wrench YW-06551 YW-06550 90890-06550 YW-06551 90890-06551 90890-06551 2 Flywheel holder YW-06550 90890-06550 3 Universal puller YB-06117 4 Flywheel puller YB-06117 90890-06521 90890-06521 5 Drive shaft holder (impeller) YB-06151 Drive shaft holder 5 (impeller) 90890-06519 6 Slide hammer and adapters (jet pump bearing)
Page 77 SPECIAL SERVICE TOOLS INFO C Outer race installer—forward gear (jet pump oil seal) YB-06085 90890-06634 YB-06085 D Ball bearing attachment (jet pump oil seal) 90890-06634 E Driver handle—large (intermediate shaft and jet pump) YB-06071 F Driver rod LS YB-06071 90890-06606 (intermediate shaft and jet pump) 90890-06606 G Drive shaft needle bearing depth stop...
Page 78 SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ............... 2-1 MAINTENANCE SPECIFICATIONS ............... 2-3 ENGINE ....................2-3 JET PUMP UNIT ..................2-4 HULL AND HOOD ..................2-5 ELECTRICAL .................... 2-5 TIGHTENING TORQUES ................2-8 SPECIFIED TORQUES................2-8 GENERAL TORQUE ................2-14 CABLE AND HOSE ROUTING ..............2-15...
Page 79: Specifications
SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit GP1300R Model code Hull Engine/jet Dimensions Length mm (in) 2,930 (115.4) Width mm (in) 1,150 (45.3) Height mm (in) 1,020 (40.2) Dry weight kg (lb) 297 (653) Maximum capacity Person/kg (lb) 2/160 (353) Performance Maximum output kW (PS) at r/min...
Page 80 Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 Research Octane Number YAMALUBE 2-W has been developed for this watercraft and it is available at a Yamaha dealer. CAUTION: Use only YAMALUBE 2-W oil. Using another oil can seriously damage the catalytic converter...
Page 81: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit GP1300R Cylinder head Warpage limit mm (in) 0.05 (0.002) Minimum compression 640 (6.4, 91) pressure (kgf/cm , psi) Cylinders Bore size mm (in) 84.000–84.018 (3.3071–3.3078) Taper limit mm (in) 0.080 (0.0031) Out-of-round limit mm (in) 0.050 (0.0020)
Page 82: Jet Pump Unit
SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Crankshaft assembly Crank width A mm (in) 72.95–73.00 (2.872–2.874) Deflection limit B mm (in) 0.05 (0.002) Deflection limit C mm (in) 0.15 (0.006) Big end side clearance D mm (in) 0.250–0.750 (0.0098–0.0295) Maximum small end axial mm (in) 2.000 (0.0787) play E...
Page 83: Hull And Hood
SPEC MAINTENANCE SPECIFICATIONS HULL AND HOOD Model Item Unit GP1300R Free play YPVS cable slack mm (in) 0.5–1.5 (0.02–0.06) Throttle lever free play mm (in) 4–7 (0.16–0.28) ELECTRICAL Model Item Unit GP1300R Battery Type Fluid Voltage, capacity V, Ah 12, 19 Specific gravity 1.28 ECM unit...
Page 84 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Ignition coil Minimum spark gap mm (in) 10–11 (0.39–0.43) Ω Primary coil resistance 0.26–0.36 (B/W – body) Secondary coil resistance kΩ 3.5–4.7 (B/W – spark plug lead terminal) Spark plug lead resistance kΩ 6.1–14.3 kΩ...
Page 85 SPEC MAINTENANCE SPECIFICATIONS Model Item Unit GP1300R Exhaust temperature sensor resistance at 300 °C (572 °F) kΩ 73–241 at 600 °C (1,112 °F) kΩ 0.86–1.58 Ω at 900 °C (1,652 °F) 64–90 Cooling water temperature sensor resistance at 0 °C (32 °F) kΩ...
Page 86: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Fuel system Strap/fuel tank/oil tank – hull Bolt Oil filler hose screw clamp — — 0.06 0.32 Retainer/fuel pump module —...
Page 87 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Muffler stay 2 – crankcase Bolt Muffler – muffler stay 2 Bolt Exhaust temperature sensor — — Cooling water temperature sensor — —...
Page 88 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb 0.38 Ground lead – Bolt cylinder head 0.76 Exhaust chamber stay/ Bolt cylinder head – cylinder Cylinder head – cylinder Bolt Anode – cylinder head Screw 0.44 Engine temperature sensor –...
Page 89 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Jet thrust nozzle – nozzle ring Bolt Spout hose screw clamp — — 0.12 Nozzle/impeller duct assembly – Bolt impeller housing 1 Water inlet cover/water inlet Bolt 0.66...
Page 90 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Steering cable locknut — — 0.65 (jet thrust nozzle end) Steering cable – hull — 0.59 Steering cable holder – bracket Bolt 0.64 Speed sensor lead –...
Page 91 SPEC TIGHTENING TORQUES Tightening torques Thread Part to be tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Electrical Tapping Cover – electrical box ø6 0.49 screw Tapping Lead retainer – electrical box ø6 0.49 screw Positive battery lead – starter relay Bolt 0.34 Starter motor lead –...
Page 92: General Torque
SPEC TIGHTENING TORQUES GENERAL TORQUE General torque This chart specifies tightening torques for stan- Nut A Bolt B specifications dard fasteners with a standard ISO thread N•m kgf•m ft•lb pitch. Tightening torque specifications for spe- 8 mm cial components or assemblies are provided in 10 mm applicable sections of this manual.
Page 93: Cable And Hose Routing
SPEC CABLE AND HOSE ROUTING CABLE AND HOSE ROUTING È É Ê Í Î Ë Ì Ì 1 Fuel tank breather hose 0 Exhaust temperature sensor I Electrical bilge pump lead 2 Cooling water pilot outlet J Wire harness (generator) lead 3 YPVS servomotor A Negative battery lead...
Page 94 SPEC CABLE AND HOSE ROUTING È É Ê Í Î Ë Ì Ì È Align the parting line on the fuel filler neck with the lot mark on the fuel filler hose. É To wire harness Ê To ventilation socket Ë...
Page 95 SPEC CABLE AND HOSE ROUTING È É Ê Ì Ë P Î Í 1 Buzzer lead A Negative battery lead K Fuel pump coupler 2 Throttle cable B Starter motor lead L Atmospheric pressure sensor 3 YPVS servomotor C Speed sensor coupler coupler 4 YPVS cables D Oil level sensor coupler...
Page 96 SPEC CABLE AND HOSE ROUTING È É Ê Ì Ë P Î Í È To cylinder #3 É To cylinder #2 Ê To cylinder #1 Ë Cooling water temperature sensor Ì Exhaust temperature sensor Í To positive battery terminal Î To starter motor 2-18...
Page 97 SPEC CABLE AND HOSE ROUTING È 1 Bilge hose 1 A Electrical bilge pump lead 2 Bilge hose 2 3 Steering cable È Contact the corrugated tube (bilge hose 1) to 4 Bilge hose 3 the hose screw clamp. 5 QSTS cable 6 Bilge hose 4 7 Cooling water hose (cooling water inlet) 8 Flushing hose...
Page 98 SPEC CABLE AND HOSE ROUTING Ê È É Ë Ò Ó Ì Ñ Í Ð Ï Î 1 Oil delivery hose #1 Ê Fasten the sub-wire harness with the plastic tie 2 Sub-wire harness on the rib of the fuel rail. Be sure to position the 3 Oil delivery hose #3 plastic tie so that the fastener is visible from the 4 Oil delivery hose #2...
Page 99 SPEC CABLE AND HOSE ROUTING Ê È É Ë Ò Ó Ì Ñ Í Ð Ï Î Î Push the corrugated tube toward the oil pump, Ó Pass the bleed hose under the exhaust cham- and then tape it. ber bracket. Be sure to install the L-shaped Ï...
Page 100 SPEC CABLE AND HOSE ROUTING Ð Ê Ë É È Ì Ñ Í Ï Î Ï Î Ò Ö Õ Ó Ô × Ï Û Ú Ù Ü Ø 15˚ 15˚ Ï 20˚ 1 Cooling water hose Ë To cooling water pilot outlet on starboard side Ì...
Page 101 SPEC CABLE AND HOSE ROUTING Ð Ê Ë É È Ì Ñ Í Ï Î Ï Î Ò Ö Õ Ó Ô × Ï Û Ú Ù Ü Ø 15˚ 15˚ Ï 20˚ Ð Contact the corrugated tube to the hose screw Ø...
Page 102 INSP CHAPTER 3 PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART .............. 3-1 PERIODIC SERVICE ..................3-2 CONTROL SYSTEM ................. 3-2 Steering column inspection ..............3-2 Steering cable inspection and adjustment .......... 3-2 Throttle cable inspection and adjustment..........3-3 QSTS cable inspection and adjustment ..........3-4 Trolling speed check ................3-5 FUEL SYSTEM..................
Page 103: Maintenance Interval Chart
INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance. Adjust the maintenance intervals according to the operating conditions of the watercraft. THEREAFTER MAINTENANCE INTERVAL INITIAL PAGE EVERY 10 hours 50 hours 100 hours 100 hours 200 hours ITEM 6 months months...
Page 104: Periodic Service
INSP CONTROL SYSTEM PERIODIC SERVICE CONTROL SYSTEM Steering column inspection 1. Check: • Steering column Excessive play → Replace the steering column. Refer to “STEERING COLUMN” in Chapter 8. Checking steps: • Move the handlebar up and down and back and forth. •...
Page 105: Throttle Cable Inspection And Adjustment
INSP CONTROL SYSTEM WARNING The cable joint must be screwed in a minimum of 8 mm (0.31 in). • Connect the cable joint, and then tighten the locknut. Locknut: 6.8 N • m (0.68 kgf • m, 4.9 ft • lb) NOTE: If the steering cable cannot be properly adjusted by the cable joint at the steering col-...
Page 106: Qsts Cable Inspection And Adjustment
INSP CONTROL SYSTEM QSTS cable inspection and adjustment 1. Measure: • Jet thrust nozzle set lengths a and b Out of specification → Adjust. Measurement steps: • Set the control grip to the neutral posi- tion. • Set the jet thrust nozzle in the center position.
Page 107: Trolling Speed Check
INSP CONTROL SYSTEM NOTE: If the QSTS cable cannot be properly adjusted by the cable joint at the QSTS converter end, adjust the cable joint at the jet pump end so that the same lengths are obtained. Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD”...
Page 108 Refer to “JET PUMP UNIT” in Chapter 6. • Check the diagnostic codes in the “Diag- nosis Record” and check for any mal- functions using the “Static Test” and “Active Test” of the Yamaha Diagnostic System. Refer to “INTRODUCTION” in Chapter...
Page 109: Fuel System
INSP FUEL SYSTEM FUEL SYSTEM WARNING When removing fuel system parts, wrap them in a cloth and take care that no fuel spills into the engine compartment. Fuel line inspection 1. Check: • Fuel pump filter Clog/contaminants → Clean. Refer to “FUEL TANK AND FUEL PUMP MODULE”...
Page 110: Oil Injection System
INSP OIL INJECTION SYSTEM OIL INJECTION SYSTEM Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses • Oil tank • Oil filler cap Cracks/damage → Replace. •...
Page 111: Power Unit
INSP POWER UNIT POWER UNIT Spark plug inspection 1. Check: • Electrodes 1 Damage/wear → Replace. • Insulator color 2 Distinctly different color → Check the condition of the engine. Color guide: Medium-to-light tan color: Normal Whitish color: Lean air-fuel mixture Air leakage Incorrect settings Blackish color:...
Page 112: Ypvs Cable Adjustment
INSP POWER UNIT 4. Tighten: • Spark plugs Spark plug: 25 N • m (2.5 kgf • m, 18 ft • lb) NOTE: • Before installing a spark plug, clean the gas- ket surface and spark plug surface. Also, it is suggested to apply a thin coat of anti-seize compound to the spark plug threads to pre- vent thread seizure.
Page 113 INSP POWER UNIT 2. Measure: • YPVS cable slack a Out of specification → Adjust. YPVS cable slack: 0.5–1.5 mm (0.02–0.06 in) 3. Adjust: • YPVS cables 1 and 2 Adjustment steps: • Loosen locknuts 1 and 2. • Turn adjusters 3 and 4 in until there is slack in the cables.
Page 114: Electrical
INSP ELECTRICAL ELECTRICAL Battery inspection WARNING • Battery electrolyte is poisonous and dan- gerous, causing severe burns, etc. Elec- trolyte contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidotes External: Flush with water. Internal: Drink large quantities of water or milk.
Page 115 INSP ELECTRICAL 1. Remove: • Battery bands • Negative battery lead 1 • Positive battery lead 2 • Battery • Battery breather hose 3 WARNING • When removing the battery, disconnect the negative lead first. • Remove the battery to prevent acid loss before turning the watercraft on its side to service the impeller, etc.
Page 116 INSP ELECTRICAL 3. Check: • Specific gravity Out of specification → Charge. Specific gravity at 20 °C (68 °F): 1.28 Charging current: 1.9 A × 10 h (68.4 kC) 4. Install: • Filler caps CAUTION: Before installing the battery, rinse off any electrolyte from the battery box or battery and make sure that the battery is dry.
Page 117: Jet Pump Unit
INSP JET PUMP UNIT JET PUMP UNIT Impeller inspection 1. Check: • Impeller 1 Damage/wear → Replace. Nicks/scratches → File or grind. 2. Measure: • Impeller-to-housing clearance a Out of specification → Replace. Maximum impeller-to-housing clearance: 0.9 mm (0.035 in) Measurement steps: •...
Page 118: Bilge Pump
INSP BILGE PUMP BILGE PUMP Bilge strainer inspection 1. Check: • Bilge strainer Contaminants → Clean. Cracks/damage → Replace. Checking steps: • Remove the bilge strainer case 1 from the bilge strainer. • Check the bilge strainer and bilge strainer case.
Page 119: General
Before lubricating the throttle cable, squeeze the throttle lever and remove the rubber seal 2. Lubricate: • QSTS control cables (handlebar end) Recommended lubricant: Yamaha marine grease, Yamaha grease A (water-resistant grease) NOTE: Before lubricating the QSTS control cables, remove the QSTS cable housing cover. Spray the rust inhibitor into the outer cables, and apply grease to the inner cables.
Page 120 INSP GENERAL 3. Lubricate: • QSTS cables (pulley end) • YPVS cables Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) 4. Lubricate: • Nozzle pivot shaft • Steering cable (jet thrust nozzle end) • QSTS cable (jet thrust nozzle end)
Page 121 INSP GENERAL 6. Fill: • Intermediate housing Recommended grease: Yamaha marine grease, Yamaha grease A (water-resistant grease) Grease quantity: 33.0–35.0 cm (1.11–1.18 oz) NOTE: Using a grease gun, fill the intermediate hous- ing with the recommended grease through the grease nipples.
Page 122 FUEL CHAPTER 4 FUEL SYSTEM OIL TANK ......................4-1 EXPLODED DIAGRAM ................4-1 REMOVAL AND INSTALLATION CHART ..........4-1 SERVICE POINTS ..................4-3 Oil line inspection ................4-3 Oil level sensor inspection ..............4-3 Oil tank inspection................4-3 FUEL TANK AND FUEL PUMP MODULE............4-4 EXPLODED DIAGRAM ................4-4 REMOVAL AND INSTALLATION CHART ..........
Page 123 FUEL OIL PUMP...................... 4-24 EXPLODED DIAGRAM ................4-24 REMOVAL AND INSTALLATION CHART ..........4-24 SERVICE POINTS .................. 4-27 Oil pump inspection................4-27 Oil hose inspection................4-27 Check valve inspection ..............4-27 Oil pump lever position adjustment ...........4-28 Oil pump bleeding ................4-29...
Page 124: Oil Tank
FUEL OIL TANK OIL TANK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL TANK REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER” in Chapter 8.
Page 125 FUEL OIL TANK EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Breather hose Oil hose Bolt Strap Oil tank Hose screw clamp Oil filler hose Oil level sensor Reverse the removal steps for installation.
Page 126: Service Points
FUEL OIL TANK SERVICE POINTS Oil line inspection 1. Check: • Oil filter Contaminants → Clean. Frays/tears → Replace. • Rubber seal Cracks/wear → Replace. • Oil hoses • Oil filler cap Cracks/damage → Replace. • Check valve Faulty → Replace. Oil level sensor inspection Refer to “INDICATION SYSTEM”...
Page 127: Fuel Tank And Fuel Pump Module
FUEL FUEL TANK AND FUEL PUMP MODULE FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) (VENT) 3.7 N •...
Page 128 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) (VENT) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.9 N •...
Page 129 FUEL FUEL TANK AND FUEL PUMP MODULE EXPLODED DIAGRAM 3.2 N • m (0.32 kgf • m, 2.3 ft • Ib) 2nd 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) (VENT) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 5.9 N •...
Page 130: Service Points
FUEL FUEL TANK AND FUEL PUMP MODULE SERVICE POINTS Fuel hose disconnection 1. Disconnect: • Fuel hose Refer to “FUEL INJECTION SYSTEM.” Fuel pump module removal 1. Remove: • Nuts • Retainer NOTE: Loosen the nuts in the sequence shown. 2.
Page 131: Check Valve Inspection
FUEL FUEL TANK AND FUEL PUMP MODULE Check valve inspection 1. Check: • Check valve Faulty → Replace. Checking steps: • Connect a hose to end “A” of the check valve, and then blow into the hose. Air should come out from end “B.” •...
Page 132: Intake Duct And Intake Silencer
FUEL INTAKE DUCT AND INTAKE SILENCER INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE DUCT AND INTAKE Follow the left “Step” for removal. SILENCER REMOVAL Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY”...
Page 133 FUEL INTAKE DUCT AND INTAKE SILENCER EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt/collar/grommet 1/1/1 Intake duct Reverse the removal steps for installation. 4-10...
Page 134: Service Points
FUEL INTAKE DUCT AND INTAKE SILENCER SERVICE POINTS Intake silencer installation 1. Install: • Intake silencer pipe • Intake silencer pipe screw clamps 1 • Intake silencer • Intake silencer screw clamp 2 NOTE: Set the screw clamps in the direction shown. 4-11...
Page 135: Fuel Injection System
FUEL FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM EXPLODED DIAGRAM 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 8 × 30 mm 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
Page 136 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 8 × 30 mm 9.0 N • m (0.9 kgf • m, 6.5 ft • Ib) 2nd 18 N • m (1.8 kgf • m, 13 ft • Ib) Step Procedure/Part name Q’ty...
Page 137 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points INTAKE SILENCER CASE AND Follow the left “Step” for removal. THROTTLE BODIES REMOVAL Intake air temperature sensor coupler Intake silencer case screw clamp Tighten the screw clamp until there is no clearance between the spacer and the screw clamp.
Page 138 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 0.8 N • m (0.08 kgf • m, 0.6 ft • Ib) 5 × 12 mm 7.5 N • m (0.75 kgf • m, 5.4 ft • Ib) 6 × 30 mm 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
Page 139 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6 × 60 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points THROTTLE BODIES Follow the left “Step” for disassembly. DISASSEMBLY Hose clamp Not reusable...
Page 140 FUEL FUEL INJECTION SYSTEM EXPLODED DIAGRAM 8.8 N • m (0.88 kgf • m, 6.4 ft • Ib) 6 × 60 mm Step Procedure/Part name Q’ty Service points Fuel injector O-ring Not reusable Throttle bodies Reverse the disassembly steps for assembly.
Page 141: Service Points
FUEL FUEL INJECTION SYSTEM SERVICE POINTS Hose clamp removal 1. Remove: • Hose clamps CAUTION: If the hose clamps are removed without cutting the crimp first, the fuel hose can be damaged. Hose clamp installation 1. Install: • Hose clamps WARNING Do not reuse the hose clamps, always replace them with new ones.
Page 142: Fuel Line Inspection
FUEL FUEL INJECTION SYSTEM CAUTION: • Do not rotate the quick connector tab 1 past the stopper position a, otherwise the tab can be damaged. • When the fuel hoses are disconnected, quickly remove the retainer 2 from the quick connector, otherwise the retainer can be lost.
Page 143: Fuel Injector Inspection
90890-03174 Fuel injector resistance (reference data): 13.8 Ω at 21 °C (70 °F) 3. Check the operation of the fuel injector using the “Stationary Test” of the Yamaha Diagnostic System. Throttle body inspection 1. Check: • Throttle body Cracks/damage → Replace the throttle bodies.
Page 144: Fuel Hose Installation (Replacing With New Fuel Hose)
FUEL FUEL INJECTION SYSTEM Fuel hose installation (replacing with new fuel hose) 1. Install: • Quick connector 1 NOTE: To install the fuel hose, be sure to align the lot mark a on the fuel hose and the checker tab 2 on the quick connector with the crimped section b of the clamp.
Page 145: Fuel Hose Connection
FUEL FUEL INJECTION SYSTEM Fuel hose connection 1. Apply a thin coat of engine oil to the con- tact surfaces of the fuel pipe. 2. Insert the quick connector into the fuel pipe until you hear a “click.” 3. To check the connection of the quick con- nector, push and pull on the quick connec- tor several times until there is free play of 2–3 mm (0.08–0.12 in).
Page 146 FUEL FUEL INJECTION SYSTEM 3. Start the engine and warm it up for several minutes. 4. Measure: • Fuel pressure Out of specification → Replace the fuel pump module. Fuel pressure: 320.8–327.2 kPa (3.21–3.27 kgf/cm 45.62–46.53 psi) 5. Remove: • Fuel pressure gauge •...
Page 147: Oil Pump
FUEL OIL PUMP OIL PUMP EXPLODED DIAGRAM 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 5 × 10 mm 6 × 20 mm 2.2 N •...
Page 148 FUEL OIL PUMP EXPLODED DIAGRAM 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 6 × 12 mm 11 N • m (1.1 kgf • m, 8.0 ft • Ib) 5 × 10 mm 6 × 20 mm 2.2 N •...
Page 149 FUEL OIL PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points OIL PUMP HOSES AND CABLE Follow the left “Step” for removal. REMOVAL Bleed hose Air bleed screw Gasket Bleed hose stay Oil delivery hose Oil delivery hose #1 Oil delivery hose #2 Oil delivery hose #3 Check valve...
Page 150: Service Points
FUEL OIL PUMP SERVICE POINTS Oil pump inspection 1. Check: • Oil pump Contaminants → Clean. Damage/wear → Replace. • Oil pump joint piece Damage/wear → Replace the oil pump. Oil hose inspection 1. Check: • Oil hoses Cracks/damage → Replace. CAUTION: •...
Page 151: Oil Pump Lever Position Adjustment
FUEL OIL PUMP Oil pump lever position adjustment 1. Check: • Oil pump lever position Incorrect → Adjust. Checking steps: • Remove the intake duct. Refer to “INTAKE DUCT AND INTAKE SILENCER.” • Squeeze the throttle lever to fully open the throttle valve lever.
Page 152: Oil Pump Bleeding
FUEL OIL PUMP Oil pump bleeding 1. Bleed: • Oil pump Bleeding steps: • Place rags around the air bleed screw 1 to catch any oil that might spill. • Fill the oil tank with the recommended oil. NOTE: If the oil pump is replaced or when the oil suction hose and oil delivery hoses are dis- connected from the oil pump, fill the hoses with oil, and then connect them to the oil...
Page 153 POWR CHAPTER 5 POWER UNIT COMPRESSION PRESSURE MEASUREMENT ..........5-1 SERVICE POINTS ..................5-1 MUFFLER ASSEMBLY ................... 5-3 EXPLODED DIAGRAM ................5-3 REMOVAL AND INSTALLATION CHART ..........5-3 SERVICE POINTS ..................5-9 Catalytic converter inspection ............. 5-9 Muffler installation ................5-9 EXHAUST CHAMBER ASSEMBLY..............5-10 EXPLODED DIAGRAM ................5-10 REMOVAL AND INSTALLATION CHART ..........
Page 154 POWR CYLINDER HEAD..................5-25 EXPLODED DIAGRAM ................5-25 REMOVAL AND INSTALLATION CHART ..........5-25 SERVICE POINTS .................. 5-27 Cylinder head inspection..............5-27 CYLINDERS ....................5-28 EXPLODED DIAGRAM ................5-28 REMOVAL AND INSTALLATION CHART ..........5-28 SERVICE POINTS .................. 5-30 Cylinder inspection................5-30 PISTONS ....................... 5-31 EXPLODED DIAGRAM ................5-31 REMOVAL AND INSTALLATION CHART ..........
Page 155: Compression Pressure Measurement
POWR COMPRESSION PRESSURE MEASUREMENT COMPRESSION PRESSURE MEASUREMENT SERVICE POINTS The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Start the engine and warm it up until the engine temperature is 48 °C (118 °F). 2.
Page 156 POWR COMPRESSION PRESSURE MEASUREMENT 6. Measure: • Compression pressure Out of specification → Refer to steps (b) and (c). Minimum compression pressure (reference data): 640 kPa (6.4 kgf/cm , 91 psi) Measurement steps: a. With the throttle wide open, crank the engine until the reading on the compres- sion gauge stabilizes.
Page 157 POWR MUFFLER ASSEMBLY MUFFLER ASSEMBLY EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm É È REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER REMOVAL Follow the left “Step” for removal. YPVS servomotor and YPVS Refer to “YPVS SERVOMOTOR”...
Page 158: Muffler Assembly
POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 6 × 22 mm É È Step Procedure/Part name Q’ty Service points È To cooling water pilot outlet (port) Screw clamp/cooling water hose Route the cooling hose under the exhaust chamber assembly.
Page 159 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Outer exhaust joint screw clamp Slide the outer exhaust joint off. Inner exhaust joint screw clamp Exhaust joint screw clamp Water lock band Slide the water lock off. Bolt Intermediate housing grease hose NOTE: To ease removal of the muffler assembly,...
Page 160 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Bolt Bolt Muffler stay 2 NOTE: Muffler assembly Remove the cylinder head if it is difficult to remove the muffler assembly. Outer exhaust joint Inner exhaust joint Reverse the removal steps for installation.
Page 161 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points MUFFLER DISASSEMBLY Follow the left “Step” for disassembly. Exhaust temperature sensor Cooling water temperature sensor Bolt Muffler stay Dowel pin Bolt Cover Gasket Not reusable Catalytic converter housing Gasket Not reusable...
Page 162 POWR MUFFLER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Catalytic converter Gasket Not reusable Bolt Mixing joint Gasket Not reusable Muffler Reverse the disassembly steps for assembly.
Page 163: Service Points
POWR MUFFLER ASSEMBLY SERVICE POINTS Catalytic converter inspection 1. Check: • Catalytic converter Cracks/damage → Replace. Muffler installation 1. Install: • Inner exhaust joint • Outer exhaust joint • Muffler assembly • Inner exhaust joint screw clamp • Outer exhaust joint screw clamp NOTE: •...
Page 164: Exhaust Chamber Assembly
POWR EXHAUST CHAMBER ASSEMBLY EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER Follow the left “Step” for removal. ASSEMBLY REMOVAL Muffler assembly Refer to “MUFFLER ASSEMBLY.” È To cooling water pilot outlet (starboard) Screw clamp/cooling water hose É...
Page 165 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Ê From exhaust manifold Screw clamp/cooling water hose NOTE: Exhaust chamber assembly Before installing the exhaust chamber assembly, connect the cooling water hose and fasten it with the screw clamp to the exhaust chamber (part 8) and place the bolts (part 3) in the bolt holes in the exhaust chamber assembly.
Page 166 POWR EXHAUST CHAMBER ASSEMBLY EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST CHAMBER Follow the left “Step” for disassembly. DISASSEMBLY Bolt Bolt Exhaust chamber joint Gasket Not reusable Exhaust chamber Reverse the disassembly steps for assembly.
Page 167: Engine Unit
POWR ENGINE UNIT ENGINE UNIT EXPLODED DIAGRAM 7.9 N • m (0.79 kgf • m, 5.7 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty...
Page 168 POWR ENGINE UNIT EXPLODED DIAGRAM 7.9 N • m (0.79 kgf • m, 5.7 ft • Ib) 6 × 25 mm 17 N • m (1.7 kgf • m, 12 ft • Ib) 8 × 40 mm Step Procedure/Part name Q’ty Service points Oil return hose...
Page 169: Service Points
POWR ENGINE UNIT SERVICE POINTS Shim removal 1. Remove: • Shims NOTE: To ease reassembly and coupling alignment, remove the shims and organize them in their respective groups (e.g., front right, rear left) prior to removing the mounting bolts. Engine mount inspection 1.
Page 170: Exhaust Manifold
POWR EXHAUST MANIFOLD EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT.” Bolt Bolt Exhaust manifold Gasket Not reusable Reverse the removal steps for installation. 5-16...
Page 171: Exploded Diagram
POWR EXHAUST MANIFOLD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points EXHAUST MANIFOLD Follow the left “Step” for disassembly. DISASSEMBLY Screw clamp/cooling water hose Bolt Cooling water joint O-ring Not reusable Exhaust manifold Reverse the disassembly steps for assembly.
Page 172 POWR REED VALVES REED VALVES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REED VALVE REMOVAL Follow the left “Step” for removal. Throttle bodies assembly Refer to “FUEL INJECTION SYSTEM” in Chapter 4. Oil delivery hoses Refer to “OIL PUMP”...
Page 173 POWR REED VALVES EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Balance plate Gasket Not reusable Reed valve plate Reed valve assembly Screw Valve stopper Reed valve Reverse the removal steps for installation. 5-19...
Page 174: Service Points
POWR REED VALVES SERVICE POINTS Reed valve inspection 1. Check: • Reed valves Cracks/damage → Replace. 2. Measure: • Valve warpage a Out of specification → Replace. Valve warpage limit: 1.5 mm (0.059 in) 3. Measure: • Valve stopper height b Out of specification →...
Page 175: Ypvs
POWR YPVS YPVS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS REMOVAL Follow the left “Step” for removal. Exhaust chamber assembly Refer to “EXHAUST CHAMBER ASSEMBLY.” Bolt YPVS valve cover Gasket Not reusable Spacer Link joint/cover Circlip Not reusable Washer...
Page 176 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: Bolt For installation, align the hole a in the YPVS shaft with the bolt. Shaft 3 Shaft 2 Shaft 1 YPVS valve arm Bolt 5-22...
Page 177 POWR YPVS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: YPVS valve assembly Install the YPVS valves with the recess b facing toward the stern. NOTE: Oil seal If the YPVS shaft is removed, the oil seal must be replaced. Reverse the removal steps for installation.
Page 178: Service Points
POWR YPVS SERVICE POINTS YPVS valve inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the surfaces. 2. Check: • YPVS valve assembly Cracks/damage/wear → Replace. YPVS valve installation 1.
Page 179: Cylinder Head
POWR CYLINDER HEAD CYLINDER HEAD EXPLODED DIAGRAM 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 22 N •...
Page 180 POWR CYLINDER HEAD EXPLODED DIAGRAM 3.8 N • m (0.38 kgf • m, 2.7 ft • Ib) 22 N • m (2.2 kgf • m, 16 ft • Ib) 2nd 7.6 N • m (0.76 kgf • m, 5.5 ft • Ib) 2nd 22 N •...
Page 181: Service Points
POWR CYLINDER HEAD SERVICE POINTS Cylinder head inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) CAUTION: Do not use a sharp instrument to avoid damaging or scratching the cylinder head or spark plug bore threads. 2. Check: •...
Page 182: Cylinders
POWR CYLINDERS CYLINDERS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CYLINDER REMOVAL Follow the left “Step” for removal. YPVS Refer to “YPVS.” Cylinder head Refer to “CYLINDER HEAD.” Engine temperature sensor Bolt NOTE: Tighten the bolts in a crisscross pattern and in two stages.
Page 183 POWR CYLINDERS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Cylinder gasket Not reusable Reverse the removal steps for installation. 5-29...
Page 184: Service Points
POWR CYLINDERS SERVICE POINTS Cylinder inspection 1. Eliminate: • Carbon deposits (using a rounded scraper 1) 2. Check: • Cylinder water jacket Corrosion/mineral deposits → Clean or replace. • Cylinder inner surface Score marks → Replace. 3. Measure: • Cylinder bore “D” (using a cylinder gauge) Out of specification →...
Page 185: Pistons
POWR PISTONS PISTONS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PISTON REMOVAL Follow the left “Step” for removal. Cylinders Refer to “CYLINDERS.” Piston pin clip Not reusable CAUTION: Do not align the open end of the clip with the piston pin slot a.
Page 186 POWR PISTONS EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bearing Piston ring CAUTION: Align each end gap with its respective locating pin. Reverse the removal steps for installation. 5-32...
Page 187: Service Points
POWR PISTONS SERVICE POINTS Piston pin clip removal and installation 1. Remove and install: • Piston pin clip NOTE: Before removing or installing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase.
Page 188: Cylinder And Piston Combination
POWR PISTONS 4. Calculate: • Piston-to-cylinder clearance Out of specification → Replace the pis- ton, piston rings, and cylinder as a set. PISTON CYLINDER PISTON – CLEARANCE BORE DIAMETER Piston-to-cylinder clearance: 0.100–0.105 mm (0.0039–0.0041 in) Cylinder and piston combination Select the appropriate piston to match the cyl- inder size from the table as follows.
Page 189: Piston Pin And Bearing Inspection
POWR PISTONS 2. Measure: • End gap (using a thickness gauge 1) Out of specification → Replace the pis- ton rings as a set. End gap: 0.45–0.60 mm (0.018–0.024 in) NOTE: Push the piston ring into the cylinder with the piston crown.
Page 190: Piston Installation
POWR PISTONS 4. Check: • Piston-pin-to-small-end-bearing-to- connecting-rod free play (at the small end of the connecting rod as shown) Free play/wear at the small end → Replace the piston pin, connecting rod, small end bearing, or all parts. Piston installation 1.
Page 191 POWR GENERATOR AND STARTER MOTOR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR COVER REMOVAL Follow the left “Step” for removal. Oil pump Refer to “OIL PUMP” in Chapter 4. Bolt Bolt NOTE: Do not apply locking agent to the bolt that is...
Page 192: Generator And Starter Motor
POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Exhaust chamber bracket Reverse the removal steps for installation. 5-38...
Page 193 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 35 mm 5 ×...
Page 194 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM 5 × 14 mm 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 5 × 14 mm 14 N • m (1.4 kgf • m, 10 ft • Ib) 6 × 35 mm 5 ×...
Page 195 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points GENERATOR ROTOR AND Follow the left “Step” for removal. STARTER MOTOR REMOVAL Drive coupling Flywheel magneto bolt NOTE: Flywheel magneto Degrease the flywheel magneto where it is Woodruff key coupled to the crankshaft.
Page 196 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Negative battery lead Nut/washer Starter motor lead Starter motor Reverse the removal steps for installation. 5-42...
Page 197 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER CLUTCH Follow the left “Step” for disassembly. DISASSEMBLY Clip Not reusable Clip stopper Spring seat Spring Washer Idle gear Circlip Plate 5-43...
Page 198 POWR GENERATOR AND STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Weight NOTE: Spring ring Install the spring ring after installing the weights, plate, and circlip. Pinion gear Reverse the disassembly steps for assembly. 5-44...
Page 199: Service Points
POWR GENERATOR AND STARTER MOTOR SERVICE POINTS Drive coupling removal and installation 1. Remove: • Drive coupling Coupler wrench: YW-06551/90890-06551 Flywheel holder: YW-06550/90890-06550 Drive coupling: 36 N • m (3.6 kgf • m, 25 ft • lb) LOCTITE 572 NOTE: Install the drive coupling with the same special service tools that were used for removal.
Page 200: Drive Coupling Inspection
POWR GENERATOR AND STARTER MOTOR 2. Remove: È • Generator rotor Universal puller: YB-06117 Flywheel puller: 90890-06521 Set bolt: M8 × 60 mm È For USA and Canada É For Worldwide É CAUTION: To prevent damage to the engine or special service tools, screw in the flywheel puller set bolts evenly and completely so that the puller plate is parallel to the generator...
Page 201: Crankcase
POWR CRANKCASE CRANKCASE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKCASE DISASSEMBLY Follow the left “Step” for disassembly. Pistons Refer to “PISTONS.” Generator cover and starter motor Refer to “GENERATOR AND STARTER MOTOR.” Bolt Mount bracket Bolt NOTE: Tighten the bolts in the sequences shown...
Page 202 POWR CRANKCASE EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Lower crankcase Crankshaft assembly Upper crankcase Reverse the disassembly steps for assembly. 5-48...
Page 203: Service Points
POWR CRANKCASE SERVICE POINTS Crankcase inspection 1. Check: • Mating surfaces Scratches → Replace the crankcase. • Crankcase Cracks/damage → Replace. Crankcase installation 1. Apply: • Gasket Maker (to the crankcase mating surfaces) NOTE: Before applying Gasket Maker, clean the crankcase mating surfaces.
Page 204: Exploded Diagram
POWR CRANKSHAFT CRANKSHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CRANKSHAFT REMOVAL Follow the left “Step” for removal. Crankcase Refer to “CRANKCASE.” Oil seal Not reusable Bearing Oil seal 1 Not reusable Oil seal 2 Not reusable Crankshaft assembly CAUTION:...
Page 205: Service Points
POWR CRANKSHAFT SERVICE POINTS Crankshaft inspection 1. Measure: • Crank width A Out of specification → Replace the crankshaft. Crank width: 72.95–73.00 mm (2.872–2.874 in) 2. Measure: • Deflection B (using a dial gauge) Out of specification → Replace. Maximum deflection: B 0.05 mm (0.002 in) C 0.15 mm (0.006 in) 3.
Page 206 POWR CRANKSHAFT 5. Check: • Bearings Damage/pitting → Replace. NOTE: • Before checking bearings, thoroughly clean them. • Immediately after checking the bearings, lubricate them to prevent rust. 6. Check: • Oil seals Damage/wear → Replace. 5-52...
Page 207 PUMP CHAPTER 6 JET PUMP UNIT JET PUMP UNIT....................6-1 EXPLODED DIAGRAM ................6-1 REMOVAL AND INSTALLATION CHART ..........6-1 JET THRUST NOZZLE AND NOZZLE RING ..........6-5 EXPLODED DIAGRAM ................6-5 REMOVAL AND INSTALLATION CHART ..........6-5 IMPELLER DUCT AND IMPELLER HOUSING 1 ...........6-6 EXPLODED DIAGRAM ................6-6 REMOVAL AND INSTALLATION CHART ..........
Page 208 JET PUMP UNIT PUMP JET PUMP UNIT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET PUMP UNIT REMOVAL Follow the left “Step” for removal. Bolt Bolt Intake grate Bolt Intake duct Felt seal Screw Speed sensor NOTE: Route the speed sensor lead between the jet pump unit and bilge hose 5.
Page 209 JET PUMP UNIT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Ride plate QSTS cable joint Plastic tie/bilge hose 5 Nut/washer Steering cable joint Screw clamp/spout hose Bolt Bolt...
Page 210 JET PUMP UNIT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points NOTE: Jet pump unit assembly Clean the mating surfaces before applying Dowel pin Yamabond No. 4. Impeller housing 2 Dowel pin Reverse the removal steps for installation.
Page 211 JET PUMP UNIT PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SPEED SENSOR DISASSEMBLY Follow the left “Step” for disassembly. Paddle wheel set Not reusable Speed sensor Reverse the disassembly steps for assembly.
Page 212: Jet Pump Unit
JET THRUST NOZZLE AND NOZZLE RING PUMP JET THRUST NOZZLE AND NOZZLE RING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points JET THRUST NOZZLE AND Follow the left “Step” for removal. NOZZLE RING REMOVAL Jet pump unit Refer to “JET PUMP UNIT.”...
Page 213: Exploded Diagram
IMPELLER DUCT AND IMPELLER HOUSING 1 PUMP IMPELLER DUCT AND IMPELLER HOUSING 1 EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND IMPELLER Follow the left “Step” for removal. HOUSING 1 REMOVAL Nozzle ring Refer to “JET THRUST NOZZLE AND NOZZLE RING.”...
Page 214: Exploded Diagram
IMPELLER DUCT AND IMPELLER HOUSING 1 PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Water inlet cover Seal Water inlet strainer Seal Reverse the removal steps for installation.
Page 215: Removal And Installation Chart
IMPELLER DUCT AND DRIVE SHAFT PUMP IMPELLER DUCT AND DRIVE SHAFT EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points IMPELLER DUCT AND DRIVE Follow the left “Step” for disassembly. SHAFT DISASSEMBLY Impeller Left-hand threads Spacer Bolt O-ring Washer EPNOC grease AP #0...
Page 216 IMPELLER DUCT AND DRIVE SHAFT PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Drive shaft Rear bearing Not reusable Spacer Front bearing Not reusable Oil seal Not reusable Oil seal Not reusable Impeller duct Reverse the disassembly steps for assembly.
Page 217: Service Points
IMPELLER DUCT AND DRIVE SHAFT PUMP SERVICE POINTS Drive shaft removal 1. Remove: • Impeller Drive shaft holder: YB-06151 Drive shaft holder 5: 90890-06519 NOTE: The impeller has left-hand threads. Turn the impeller clockwise to loosen it. 2. Remove: • Nut 1 Drive shaft holder: YB-06151 Drive shaft holder 5:...
Page 218: Impeller Inspection
IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Remove: • Front bearing Driver handle—large: YB-06071 Driver rod L3: 90890-06652 Bearing housing needle bearing remover: YB-06112 Needle bearing attachment: 90890-06614 NOTE: Remove the front bearing using a press. 6. Remove: • Oil seal Driver handle—large: YB-06071 Driver rod L3:...
Page 219: Drive Shaft Installation
IMPELLER DUCT AND DRIVE SHAFT PUMP Drive shaft installation 1. Install: • Oil seals Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Outer race installer—forward gear: YB-06085 Ball bearing attachment: 90890-06634 Distance a: 14.2 ± 0.2 mm (0.56 ± 0.01 in) Distance b: 4.7 ±...
Page 220 IMPELLER DUCT AND DRIVE SHAFT PUMP 5. Install: • Rear bearing Drive shaft needle bearing depth stop: YB-34474 NOTE: • Press the bearing inner/outer race at the same time holding the drive shaft and impel- ler duct. • If a bearing inner/outer race attachment is not available, use a washer or pipe with an outer diameter of 47–50 mm (1.85–1.97 in) and an inner diameter of 21–25 mm (0.83–...
Page 221: Exploded Diagram
TRANSOM PLATE AND HOSES PUMP TRANSOM PLATE AND HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TRANSOM PLATE AND HOSE Follow the left “Step” for removal. REMOVAL Exhaust system Refer to “EXHAUST SYSTEM” in Chapter 8. Jet pump unit assembly Refer to “JET PUMP UNIT.”...
Page 222 TRANSOM PLATE AND HOSES PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bilge hose 4 Band Electric bilge pump assembly Hose clamp Bilge hose 3 Bilge strainer Nut/washer Transom plate Plastic tie/bilge hose 5 Reverse the removal steps for installation. 6-15...
Page 223: Service Points
TRANSOM PLATE AND HOSES PUMP SERVICE POINTS Bilge strainer inspection Refer to “JET PUMP UNIT” in Chapter 3. Electric bilge pump inspection Refer to “BILGE PUMP” in Chapter 3. Refer to “ELECTRIC BILGE PUMP” in Chapter Bilge hose inspection 1. Check: •...
Page 224: Bearing Housing
BEARING HOUSING PUMP BEARING HOUSING EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Rubber coupling Bolt Intermediate housing assembly Shim —...
Page 225 BEARING HOUSING PUMP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BEARING HOUSING Follow the left “Step” for disassembly. DISASSEMBLY Grease hose Grease nipple Grease nipple stay Nipple Driven coupling Washer Intermediate drive shaft O-ring Not reusable 6-18...
Page 226 BEARING HOUSING PUMP EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Oil seal Not reusable Oil seal Not reusable Oil seal Not reusable Circlip Bearing Not reusable Circlip Reverse the disassembly steps for assembly. 6-19...
Page 227: Service Points
BEARING HOUSING PUMP SERVICE POINTS Driven coupling removal and installation 1. Remove and install: • Driven coupling Driven coupling: 36 N • m (3.6 kgf • m, 25 ft • lb) LOCTITE 572 Coupler wrench: YW-06551/90890-06551 Shaft holder: YB-06552 Crankshaft holder 20: 90890-06552 NOTE: Install the driven coupling with the same spe-...
Page 228: Bearing Removal
BEARING HOUSING PUMP Bearing removal 1. Remove: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: • Install the bearing with the same special ser- vice tools that were used for removal. •...
Page 229: Oil Seal Installation
BEARING HOUSING PUMP 2. Install: • Bearing Driver handle—large: YB-06071 Driver rod LS: 90890-06606 Drive shaft taper roller bearing cup installer: YB-06156 Bearing outer race attachment: 90890-06626 NOTE: Support the intermediate housing with steel blocks 1 and install the bearing using a press. Oil seal installation 1.
Page 230: Intermediate Housing Installation
BEARING HOUSING PUMP 3. Install: • Oil seal 1 [8 mm (0.31 in)] • Oil seal 2 [10 mm (0.39 in)] Distance a: 10.3–10.7 mm (0.41–0.42 in) Distance b: 1.6–2.0 mm (0.06–0.08 in) Intermediate housing installation 1. Install: • Intermediate housing •...
Page 231 – ELEC CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................ 7-1 ELECTRICAL BOX..................7-2 EXPLODED DIAGRAM ................7-2 REMOVAL AND INSTALLATION CHART ..........7-2 ECM AND SLANT DETECTION SWITCH ............7-7 EXPLODED DIAGRAM ................7-7 REMOVAL AND INSTALLATION CHART ..........7-7 ELECTRICAL ANALYSIS ................7-8 INSPECTION.....................
Page 232 – ELEC FUEL CONTROL SYSTEM ................7-23 WIRING DIAGRAM ................. 7-23 FUEL PUMP .................... 7-25 FUEL SENDER ..................7-25 FUEL INJECTOR ..................7-26 ENGINE TEMPERATURE SENSOR ............7-26 INTAKE AIR TEMPERATURE SENSOR ..........7-26 COOLING WATER TEMPERATURE SENSOR........7-26 EXHAUST TEMPERATURE SENSOR ...........7-26 MAIN AND FUEL PUMP RELAY.............
Page 233 – ELEC YPVS SERVOMOTOR...................7-39 EXPLODED DIAGRAM ................7-39 REMOVAL AND INSTALLATION CHART ..........7-39 SERVICE POINTS .................. 7-41 YPVS cable removal and installation ..........7-41 YPVS cable inspection..............7-41 YPVS servomotor inspection ............7-41 YPVS cable adjustment ..............7-41 OFF THROTTLE STEERING SYSTEM............7-42 WIRING DIAGRAM .................
Page 234: Electrical Components
– ELEC ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 1 Slant detection switch B Rectifier/regulator L Lighting coil and pickup coil 2 Fuel pump C Electric bilge pump M Engine stop switch, engine 3 Atmospheric pressure sensor D Speed sensor shut-off switch, and start 4 Multifunction meter E Battery switch...
Page 235: Electrical Box
– ELEC ELECTRICAL BOX ELECTRICAL BOX EXPLODED DIAGRAM 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 10 mm 6 × 30 mm 3.9 N •...
Page 236 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 10 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
Page 237 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 10 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
Page 238 – ELEC ELECTRICAL BOX EXPLODED DIAGRAM 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 4.9 N • m (0.49 kgf • m, 3.5 ft • Ib) 6 × 10 mm 6 × 30 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
Page 239 – ELEC ELECTRICAL BOX 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 3.4 N • m (0.34 kgf • m, 2.5 ft • Ib) 6 × 25 mm 6 × 16 mm 3.9 N • m (0.39 kgf • m, 2.8 ft • Ib) 6 ×...
Page 240: Ecm And Slant Detection Switch
– ELEC ECM AND SLANT DETECTION SWITCH ECM AND SLANT DETECTION SWITCH EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ECM AND SLANT DETECTION Follow the left “Step” for removal. SWITCH REMOVAL Nut/washer ECM coupler Nut/washer Slant detection switch Slant detection switch coupler Reverse the removal steps for installation.
Page 241: Electrical Analysis
– ELEC ELECTRICAL ANALYSIS ELECTRICAL ANALYSIS INSPECTION CAUTION: • All measuring instruments should be han- dled with special care. Damaged or mis- handled instruments will not measure properly. • On instruments powered by dry batteries, check the battery voltage periodically and replace the batteries if necessary.
Page 242: Low Resistance Measurement
– ELEC ELECTRICAL ANALYSIS Low resistance measurement NOTE: • When measuring a resistance of 10 Ω or less with the digital tester, the correct measure- ment cannot be obtained because of the tester’s internal resistance. • To obtain the correct value, subtract the internal resistance from the displayed mea- surement.
Page 243: Peak Voltage Adapter
– ELEC ELECTRICAL ANALYSIS Peak voltage adapter NOTE: • Throughout this chapter the part number of the peak voltage adapters have been omit- ted. Refer to the following part numbers. • The peak voltage adapter should be used with the digital tester. Peak volt meter adapter: YU-39991 È...
Page 244: Ignition System
– ELEC IGNITION SYSTEM IGNITION SYSTEM WIRING DIAGRAM 19 : 20 : 27 : 28 : 29 : 30 : 5 6 7 8 10 11 12 13 15 16 17 18 10 : 31 : 11 : 33 : 12 : 34 : 13 :...
Page 245 – ELEC IGNITION SYSTEM WIRING DIAGRAM 19 : 20 : 27 : 28 : 29 : 30 : 5 6 7 8 10 11 12 13 15 16 17 18 10 : 31 : 11 : 33 : 12 : 34 : 13 : 35 :...
Page 246: Ignition Spark Gap
– ELEC IGNITION SYSTEM IGNITION SPARK GAP WARNING • When checking the spark gap, do not touch any of the connections of the spark gap tester lead wires. • When performing the spark gap test, take special care not to let sparks leak out of the removed spark plug cap.
Page 247: Ignition System Peak Voltage
– ELEC IGNITION SYSTEM IGNITION SYSTEM PEAK VOLTAGE WARNING When checking the electrical components, do not touch any of the connections of the digital tester lead wires. NOTE: • If there is no spark, or the spark is weak, continue with the ignition system test. •...
Page 248 – ELEC IGNITION SYSTEM 2. Measure: • Pickup coil output peak voltage Below specification → Replace the pickup coil. Above specification → Replace the ECM. Test harness (6 pins): YB-06849 Test harness SM6195021-6 (6 pins): 90890-06849 Pickup coil output peak voltage: White/red (W/R) –...
Page 249: Battery
– ELEC IGNITION SYSTEM 4. Measure: • Rectifier/regulator output peak voltage Below specification → Replace the recti- fier/regulator. Test harness (6 pins): YB-06848 Test harness FSW-6A (6 pins): 90890-06848 Rectifier/regulator output peak voltage: Red (R) – Black (B) Unloaded r/min 3,500 14.5 NOTE:...
Page 250: Ignition Coil
– ELEC IGNITION SYSTEM IGNITION COIL 1. Measure: • Primary coil resistance Out of specification → Replace. Primary coil resistance: Black/white (B/W) – Body 0.26–0.36 Ω at 20 °C (68 °F) NOTE: When measuring a resistance of 10 Ω or less with the digital tester, the correct measurement cannot be obtained because of the tester’s internal resistance.
Page 251: Engine Temperature Sensor
– ELEC IGNITION SYSTEM ENGINE TEMPERATURE SENSOR 1. Measure: • Engine temperature sensor resistance (at the specified temperatures) Out of specifications → Replace. Engine temperature sensor resistance: 20 °C (68 °F): 54.2–69.0 kΩ 100 °C (212 °F): 3.12–3.48 kΩ Measurement steps: •...
Page 252: Cooling Water Temperature Sensor
– ELEC IGNITION SYSTEM COOLING WATER TEMPERATURE SENSOR 1. Measure: • Cooling water temperature sensor resistance (at the specified temperatures) Out of specifications → Replace. Cooling water temperature sensor resistance: 0 °C (32 °F): 24.0–37.1 kΩ 100 °C (212 °F): 0.87–1.18 kΩ 200 °C (392 °F): 104–153 Ω...
Page 253: Main And Fuel Pump Relay
4 or 7. – THROTTLE POSITION SENSOR 1. Measure: • Check the throttle position sensor output voltage using the Yamaha Diagnostic System. Out of specification → Replace the throttle bodies. Throttle position sensor output voltage: Pink (P) –...
Page 254: Atmospheric Pressure Sensor
• Operate the Yamaha Diagnostic System. • Apply vacuum pressure to the atmo- spheric pressure sensor and measure the output voltage. NOTE: While the Yamaha Diagnostic System is oper- ating, electric power is supplied to the atmo- spheric pressure sensor. 7-21...
Page 255: Slant Detection Switch
– ELEC IGNITION SYSTEM SLANT DETECTION SWITCH È 1. Check: • Slant detection switch continuity Out of specification → Replace. É Lead color Black/ Position Blue/black orange (L/B) (B/O) Normal operation È Overturned É 7-22...
Page 256: Fuel Control System
– ELEC FUEL CONTROL SYSTEM FUEL CONTROL SYSTEM WIRING DIAGRAM 24 : Pu/Y 25 : Pu/B 26 : Pu/R 27 : 28 : 10 : 29 : 5 6 7 8 11 12 13 15 16 17 18 19 14 : 30 : 20 : 31 :...
Page 257 – ELEC FUEL CONTROL SYSTEM WIRING DIAGRAM 24 : Pu/Y 25 : Pu/B 26 : Pu/R 27 : 28 : 10 : 29 : 5 6 7 8 11 12 13 15 16 17 18 19 14 : 30 : 20 : 31 : 23 :...
Page 258: Fuel Pump
– ELEC FUEL CONTROL SYSTEM FUEL PUMP 1. Check: • Fuel pump operating sound No sound → Measure the fuel pressure. Refer to “FUEL INJECTION SYSTEM” in Chapter 4. FUEL SENDER 1. Measure: • Fuel sender resistance Out of specification → Replace. Float Resistance (Ω) position...
Page 259: Fuel Injector
– ELEC FUEL CONTROL SYSTEM FUEL INJECTOR Refer to “FUEL INJECTION SYSTEM” in Chapter 4. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” INTAKE AIR TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” COOLING WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.”...
Page 260: Starting System
– ELEC STARTING SYSTEM STARTING SYSTEM WIRING DIAGRAM 27 : 33 : 5 6 7 8 10 11 12 13 15 16 17 18 W B R Br Br Br FREE FREE PUSH PUSH 1 ECM : Black 2 Main and fuel pump relay : Brown 3 Fuse (20 A) : Red...
Page 261: Battery
– ELEC STARTING SYSTEM BATTERY Refer to “ELECTRICAL” in Chapter 3. WIRING CONNECTIONS 1. Check: • Wiring connections Poor connections → Properly connect. FUSES 1. Check: • Fuses Broken → Replace. Fuse rating: 20 A × 1, 3 A × 2 NOTE: The 20 A fuse is for the main relay, engine shut-off switch, and rectifier/regulator.
Page 262: Starter Relay
– ELEC STARTING SYSTEM STARTER RELAY 1. Check: • Brown lead terminal • Black lead terminal Loose → Tighten. 2. Check: • Starter relay continuity Out of specification → Replace. Checking steps: • Connect the tester leads between the starter relay terminals as shown. •...
Page 263 – ELEC STARTER MOTOR STARTER MOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STARTER MOTOR Follow the left “Step” for disassembly. DISASSEMBLY Starter motor Refer to “GENERATOR AND STARTER MOTOR” in Chapter 5. O-ring Not reusable Bolt Starter motor front cover O-ring...
Page 264 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Starter motor rear cover O-ring Not reusable Shim — As required Thickness = 0.2 mm, 0.8 mm Armature assembly Nut/spring washer/washer 1/1/4 O-ring Not reusable Brush holder Brush spring Bolt Brush assembly 7-31...
Page 265 – ELEC STARTER MOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Spacer Holder Starter motor yoke Reverse the disassembly steps for assembly. 7-32...
Page 266: Service Points
– ELEC STARTER MOTOR SERVICE POINTS Armature inspection 1. Check: • Armature shaft 1 Damage/wear → Replace. 2. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 3. Measure: • Commutator diameter Out of specification → Replace. Minimum commutator diameter: 27.0 mm (1.06 in) 4.
Page 267: Brush Holder Inspection
– ELEC STARTER MOTOR 6. Check: • Armature coil continuity Out of specification → Replace. Armature coil continuity: Commutator segments 1 Continuity Segment – laminations 2 No continuity Segment – armature shaft No continuity Brush holder inspection 1. Measure: • Brush length a Out of specification →...
Page 268: Charging System
– ELEC CHARGING SYSTEM CHARGING SYSTEM WIRING DIAGRAM 1 Rectifier/regulator : Black 2 Fuse (20 A) : Green 3 Battery : Red 4 Lighting coil 7-35...
Page 269: Fuse
– ELEC CHARGING SYSTEM FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.” 7-36...
Page 270: Ypvs
– ELEC YPVS YPVS WIRING DIAGRAM 21 : 10 : 22 : 11 : 23 : 12 : 29 : 13 : 33 : 5 6 7 8 10 11 12 13 15 16 17 18 B/O B/O W/B B/O W/R W/Y 1 ECM : Black...
Page 271: Fuse
– ELEC YPVS FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. PICKUP COIL Refer to “IGNITION SYSTEM.” LIGHTING COIL Refer to “IGNITION SYSTEM.” RECTIFIER/REGULATOR Refer to “IGNITION SYSTEM.” 7-38...
Page 272: Ypvs Servomotor
– ELEC YPVS SERVOMOTOR YPVS SERVOMOTOR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points YPVS SERVOMOTOR REMOVAL Follow the left “Step” for removal. Bolt Cable holder YPVS servomotor coupler Nut/washer YPVS servomotor Throttle cable plastic tie bracket YPVS cable Slide the cover.
Page 273 – ELEC YPVS SERVOMOTOR EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Cover Nut/washer YPVS servomotor bracket Reverse the removal steps for installation. 7-40...
Page 274: Service Points
Frays/kinks/rough movement → Replace. YPVS servomotor inspection 1. Check: • Check the YPVS servomotor operation using the Yamaha Diagnostic System. CAUTION: Do not disassemble the YPVS servomotor unit. It is a sealed unit and if it is faulty it must be replaced.
Page 275: Off Throttle Steering System
– ELEC OFF THROTTLE STEERING SYSTEM OFF THROTTLE STEERING SYSTEM WIRING DIAGRAM 15 : 16 : 17 : 10 : 18 : 11 : 27 : 12 : 29 : 5 6 7 8 10 11 12 13 15 16 17 18 13 : 31 : R/Y R/Y...
Page 276: Steering Switch
Malfunction → Check that the steering switch switches on and off when the handlebar is turned to the right and to the left using the “Engine monitor” of the Yamaha Diagnostic System. Does not operate → Replace. STEPPING MOTOR 1. Check: •...
Page 277: Electric Bilge Pump
– ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP WIRING DIAGRAM 27 : 5 6 7 8 10 11 12 13 15 16 17 18 1 ECM : Black 2 Main and fuel pump relay : Brown 3 Fuse (3 A) : Red 4 Battery : Yellow...
Page 278: Fuse
– ELEC ELECTRIC BILGE PUMP ELECTRIC BILGE PUMP 1. Check: • Electric bilge pump operation Does not operate → Replace. Checking steps: • Suspend the electric bilge pump in a con- – tainer filled with water. • Connect the brown lead terminal to the positive battery terminal.
Page 279: Indication System
– ELEC INDICATION SYSTEM INDICATION SYSTEM WIRING DIAGRAM 20 : 27 : 29 : 32 : 33 : 5 6 7 8 10 11 12 13 15 16 17 18 B/Y B/O Pu/Y Pu/B Pu/R Pu/Y Pu/R Pu/B È 1 ECM 0 Multifunction meter 2 Main and fuel pump relay A Oil level sensor...
Page 280 – ELEC INDICATION SYSTEM WIRING DIAGRAM 20 : 27 : 29 : 32 : 33 : 5 6 7 8 10 11 12 13 15 16 17 18 B/Y B/O Pu/Y Pu/B Pu/R Pu/Y Pu/R Pu/B È : Black : Black/orange : Green : Black/red : Blue...
Page 281: Fuse
– ELEC INDICATION SYSTEM FUSE Refer to “STARTING SYSTEM.” BATTERY Refer to “ELECTRICAL” in Chapter 3. ENGINE TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” COOLING WATER TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” EXHAUST TEMPERATURE SENSOR Refer to “IGNITION SYSTEM.” MAIN AND FUEL PUMP RELAY Refer to “IGNITION SYSTEM.”...
Page 282: Buzzer
– ELEC INDICATION SYSTEM BUZZER 1. Check: • Buzzer Buzzer does not sound → Replace. Checking steps: • Connect a 12 V battery to the buzzer cou- pler as shown. Positive battery terminal → Red (R) terminal 1 Negative battery terminal → Black (B) terminal 2 MULTIFUNCTION METER Multifunction meter...
Page 283: Display Function
– ELEC INDICATION SYSTEM Display function 1. Check: • Display function Does not operate → Replace the multi- function meter. 1 Buzzer : Black 2 Speed sensor : Blue 3 ECM : Pink 4 Oil level sensor : Red 5 Fuel sender : White : Yellow : Black/red...
Page 284: Speedometer Display
• Two pulses occur every time the paddle wheel makes one full turn. Tachometer display 1. Check: • Tachometer display Does not display → Check the engine speed using the “Engine monitor” of the Yamaha Diagnostic System. If there is no malfunction, replace the multifunction meter. 7-51...
Page 285: Hour Meter Display
1. Check: • Voltage meter display Does not display → Check the battery voltage using the “Engine monitor” of the Yamaha Diagnostic System. If there is no malfunction, replace the multifunction meter. Fuel level meter display and fuel warning indicator 1.
Page 286: Engine Overheat Warning Indicator
– ELEC INDICATION SYSTEM Engine overheat warning indicator 1. Check: • Engine overheat warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the cooling water tempera- ture sensor coupler 1. •...
Page 287: Check Engine Warning Indicator
– ELEC INDICATION SYSTEM Check engine warning indicator 1. Check: • Check engine warning indicator Does not operate → Replace the multi- function meter. Checking steps: • Start the engine. • Disconnect the coupler of a sensor (e.g., atmospheric pressure sensor) that nor- mally activates the check engine warning indicator when a malfunction occurs.
Page 288 HULL HOOD CHAPTER 8 HULL AND HOOD HANDLEBAR ....................8-1 EXPLODED DIAGRAM ................8-1 REMOVAL AND INSTALLATION CHART ..........8-1 SERVICE POINTS ..................8-6 Handlebar inspection ................8-6 Handlebar switch inspection ............... 8-6 Handlebar assembly installation ............8-6 QSTS GRIP ..................... 8-8 EXPLODED DIAGRAM ................8-8 REMOVAL AND INSTALLATION CHART ..........
Page 289 HULL HOOD HOSES ......................8-27 EXPLODED DIAGRAM ................8-27 REMOVAL AND INSTALLATION CHART ..........8-27 SERVICE POINTS .................. 8-28 Check valve inspection ..............8-28 Ventilation hose installation...............8-28 SEAT AND HANDGRIP................. 8-29 EXPLODED DIAGRAM ................8-29 REMOVAL AND INSTALLATION CHART ..........8-29 SERVICE POINTS .................. 8-31 Seat lock inspection ................8-31 BATTERY BOX .....................
Page 290 HULL HANDLEBAR HOOD HANDLEBAR EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR COVER REMOVAL Follow the left “Step” for removal. Screw Handlebar cover Screw Handlebar cover stay Plastic tie Throttle cable Bolt Upper handlebar holder Handlebar assembly Lower handlebar holder Reverse the removal steps for installation.
Page 291 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR REMOVAL Follow the left “Step” for removal. QSTS cable (to jet thrust nozzle) Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.” NOTE: Grommet To ease installation, apply soapy water to the grommet.
Page 292 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Handlebar assembly Nut/washer QSTS converter Throttle cable Reverse the removal steps for installation.
Page 293 HULL HANDLEBAR HOOD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HANDLEBAR DISASSEMBLY Follow the left “Step” for disassembly. Plastic tie Bolt Grip end Spacer Screw/spring washer/washer 1/1/1 QSTS grip assembly Screw Handlebar switch assembly Spacer 1 Screw...
Page 294 HULL HANDLEBAR HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Throttle lever assembly NOTE: Handlebar grip Apply adhesive to the handlebar and the inner surface of the handlebar grip. Spacer 2 Handlebar Reverse the disassembly steps for assembly.
Page 295 HULL HANDLEBAR HOOD SERVICE POINTS Handlebar inspection 1. Check: • Handlebar Bends/cracks/damage → Replace. Handlebar switch inspection Refer to “IGNITION SYSTEM” and “START- ING SYSTEM” in Chapter 7. Handlebar assembly installation 1. Adjust: • QSTS cable length a QSTS cable length: 72 ±...
Page 296 HULL HANDLEBAR HOOD 3. Install: • Throttle cable NOTE: Fit the seal into the groove in the bracket. 4. Install: • Plastic tie 1 NOTE: After inserting the QSTS cables and throttle cable into the grommet, fasten the end of grommet with the plastic tie.
Page 297 HULL QSTS GRIP HOOD QSTS GRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points QSTS GRIP DISASSEMBLY Follow the left “Step” for disassembly. QSTS grip assembly Refer to “HANDLEBAR.” Screw/washer Cover Ball Spring QSTS cable 1 Cable 2 is identifiable by the white tape a QSTS cable 2 wrapped around it.
Page 298 HULL QSTS GRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Screw/washer Collar QSTS shift lock lever Spring Spacer QSTS cable housing cover QSTS shift grip Reverse the disassembly steps for assembly.
Page 299 HULL QSTS GRIP HOOD SERVICE POINTS QSTS cable inspection 1. Check: • QSTS cables Frays/kinks/rough movement → Replace. QSTS grip inspection 1. Check: • QSTS grip Damage/wear → Replace. 8-10...
Page 300 HULL STEERING COLUMN HOOD STEERING COLUMN EXPLODED DIAGRAM 16 N • m (1.6 kgf • m, 11 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points STEERING COLUMN REMOVAL Follow the left “Step” for removal. Steering console cover assembly Refer to “STEERING CONSOLE COVER.”...
Page 301 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 26 N • m (2.6 kgf • m, 19 ft • Ib) 8 × 60 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 16 N • m (1.6 kgf • m, 11 ft • Ib) 5.0 N •...
Page 302 HULL STEERING COLUMN HOOD EXPLODED DIAGRAM 26 N • m (2.6 kgf • m, 19 ft • Ib) 8 × 60 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 16 N • m (1.6 kgf • m, 11 ft • Ib) 5.0 N •...
Page 303 HULL STEERING COLUMN HOOD SERVICE POINTS Steering column bushing inspection 1. Check: • Bushings Damage/wear → Replace. 2. Check: • Steering column Refer to “CONTROL SYSTEM” in Chap- ter 3. Steering column assembly 1. Install: • Steering switch 1 • Screw clamp 2 •...
Page 304 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD REMOTE CONTROL CABLES AND SPEED SENSOR LEAD EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points REMOTE CONTROL CABLES Follow the left “Step” for removal. AND SPEED SENSOR LEAD REMOVAL Speed sensor coupler Screw...
Page 305 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Seal Steering cable QSTS cable end Seal QSTS cable Reverse the removal steps for installation. 8-16...
Page 306 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD SERVICE POINTS WARNING When routing the cables, do not grasp the cable by the outer crimped sheath or steel end. This could deform or loosen the cable end due to extreme angles and or pressure. Always hold the cables by the bracket or outer cover below the crimp.
Page 307 REMOTE CONTROL CABLES AND HULL SPEED SENSOR LEAD HOOD QSTS cable installation 1. Install: • QSTS cable (jet pump end) QSTS cable set length a (jet pump end): 12.0–14.0 mm (0.47–0.55 in) WARNING The QSTS cable must be screwed in a mini- mum of 8 mm (0.31 in).
Page 308 HULL HOOD HOOD HOOD EXPLODED DIAGRAM 6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 5 × 20 mm 1.0 N •...
Page 309 HULL HOOD HOOD EXPLODED DIAGRAM 6 × 14 mm 5.4 N • m (0.54 kgf • m, 3.9 ft • Ib) 6 × 14 mm 12 N • m (1.2 kgf • m, 8.7 ft • Ib) 5 × 20 mm 1.0 N •...
Page 310 HULL STEERING CONSOLE COVER HOOD STEERING CONSOLE COVER EXPLODED DIAGRAM 8 × 25 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5 × 19 mm 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 ×...
Page 311 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 8 × 25 mm 2.0 N • m (0.2 kgf • m, 1.4 ft • Ib) 5 × 19 mm 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 25 mm 5.4 N •...
Page 312 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5 × 20 mm 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 18 mm 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) REMOVAL AND INSTALLATION CHART Step Procedure/Part name...
Page 313 HULL STEERING CONSOLE COVER HOOD EXPLODED DIAGRAM 1.3 N • m (0.13 kgf • m, 0.9 ft • Ib) 5 × 20 mm 2.9 N • m (0.29 kgf • m, 2.1 ft • Ib) 6 × 18 mm 1.8 N • m (0.18 kgf • m, 1.3 ft • Ib) Step Procedure/Part name Q’ty...
Page 314 HULL BUZZER AND HOOD LOCK HOOD BUZZER AND HOOD LOCK EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BUZZER AND HOOD LOCK Follow the left “Step” for removal. REMOVAL Steering console cover assembly Refer to “STEERING CONSOLE COVER.” Steering cable Refer to “REMOTE CONTROL CABLES AND SPEED SENSOR LEAD.”...
Page 315 HULL BUZZER AND HOOD LOCK HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Hood lock assembly Grommet Atmospheric pressure sensor coupler Atmospheric pressure sensor Reverse the removal steps for installation. 8-26...
Page 316 HULL HOSES HOOD HOSES EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points HOSE REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Steering console cover assembly Refer to “STEERING CONSOLE COVER.” Plastic tie Ventilation hose Ventilation duct...
Page 317 HULL HOSES HOOD SERVICE POINTS Check valve inspection 1. Check: • Check valve Faulty → Replace. Checking steps: • Connect a hose to end “A” of the check valve, and then blow into the hose. Air should come out from end “B.” •...
Page 318 HULL SEAT AND HANDGRIP HOOD SEAT AND HANDGRIP EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SEAT AND HANDGRIP Follow the left “Step” for removal. REMOVAL Seat Bolt Seat lock Projection Washer Rubber ring Nut/washer 8-29...
Page 319 HULL SEAT AND HANDGRIP HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Bolt Handgrip Bracket Reverse the removal steps for installation. 8-30...
Page 320 HULL SEAT AND HANDGRIP HOOD SERVICE POINTS Seat lock inspection 1. Check: • Seat lock Damage/wear → Replace. 8-31...
Page 321 HULL BATTERY BOX HOOD BATTERY BOX EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points BATTERY BOX REMOVAL Follow the left “Step” for removal. Battery band Fire extinguisher container Battery band Bolt Negative battery lead Terminal extension Bolt Positive battery lead Clip/breather hose...
Page 322 HULL BATTERY BOX HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Cap nut/washer/bolt 2/2/2 Electrical box Cap nut/washer Holder Holder Cap nut/washer NOTE: Battery box Before installing the battery box, route the battery leads and battery breather hose through the holes in the battery box. Stay Reverse the removal steps for installation.
Page 323 HULL EXHAUST SYSTEM HOOD EXHAUST SYSTEM EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 ×...
Page 324 HULL EXHAUST SYSTEM HOOD EXPLODED DIAGRAM 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 3.7 N • m (0.37 kgf • m, 2.7 ft • Ib) 6.4 N • m (0.64 kgf • m, 4.6 ft • Ib) 6 ×...
Page 325 HULL EXHAUST SYSTEM HOOD SERVICE POINTS Exhaust system inspection 1. Check: • Water lock band Cracks/damage → Replace. 2. Check: • Rubber hoses Burns/cracks/damage → Replace. 3. Check: • Water lock Cracks/leaks → Replace. 4. Check: • Water tank Cracks/damage/leaks → Replace. Water lock installation 1.
Page 326 HULL EXHAUST SYSTEM HOOD Exhaust component parts assembly 1. Install: • Exhaust outlet • Rubber hose • Water tank NOTE: • Insert the exhaust outlet 45–50 mm (1.77– 1.97 in) a into the rubber hose. • Make sure that there is a distance of 10 mm (0.39 in) b between the parting lines of the exhaust outlet and the rubber hose.
Page 327 HULL DECK AND HULL HOOD DECK AND HULL EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points DECK AND HULL DISASSEMBLY Follow the left “Step” for disassembly. Bolt Bow eye Rope hole fitting Spout Bolt Sponson NOTE: Install the starboard and port side sponsons at the same position.
Page 328 HULL DECK AND HULL HOOD EXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points Bolt Flap Nut/washer Screw/washer Drain plug Seal Reverse the disassembly steps for assembly. 8-39...
Page 329 HULL ENGINE MOUNTS HOOD ENGINE MOUNTS EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points ENGINE MOUNT REMOVAL Follow the left “Step” for removal. Engine unit Refer to “ENGINE UNIT” in Chapter 5. Bolt Damper 1 Damper 2 Bolt Engine mount Liner...
Page 330 TRBL ANLS CHAPTER 9 TROUBLE ANALYSIS INTRODUCTION....................9-1 FEATURES ....................9-1 Functions..................... 9-1 CONTENTS....................9-1 HARDWARE REQUIREMENTS..............9-2 OPERATING....................9-3 CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT..................9-3 TROUBLE ANALYSIS..................9-4 TROUBLE ANALYSIS CHART..............9-4 SELF-DIAGNOSIS ..................9-7...
Page 331 ANLS INTRODUCTION FEATURES The newly developed Yamaha Diagnostic System provides quicker detection and analysis of engine malfunctions for quicker troubleshooting procedures than traditional methods. By connecting your computer to the ECM (Electronic Control Module) of a watercraft using the com- munication cable, this software can be used to display sensor data and data stored in the ECM on a computer’s monitor.
Page 332 • Window XP is a multiuser operating system, therefore, be sure to end this program if the login user is changed. • The USB adapter cannot be used with Windows 95. For operating instructions of the Yamaha Diagnostic System, refer to the “Yamaha Diagnostic Sys- tem Instruction Manual.”...
Page 333 TRBL OPERATING ANLS OPERATING CONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFT Model: GP1300R Top view 1 3-pin communication coupler 2 Wire harness coupler 3 Multifunction meter coupler NOTE: Be careful not to pinch the communication cable between the hood and the deck or to damage it.
Page 334 TRBL TROUBLE ANALYSIS ANLS TROUBLE ANALYSIS NOTE: Before consulting the “TROUBLE ANALYSIS CHART,” check the following items. 1. Check that the battery is charged and that its specified gravity is within specification. 2. Check that there are no incorrect wiring connections. 3.
Page 335 TRBL TROUBLE ANALYSIS ANLS Symptom Check items Applicable part Chapter JET PUMP UNIT Impeller duct Impeller Intake grate Bearings Intake duct Water inlet hose Bilge hoses Bilge strainer Bilge hose joints ELECTRICAL Ignition system, fuel control system • Pickup coils •...
Page 336 TRBL TROUBLE ANALYSIS ANLS Symptom Check items Applicable part Chapter Starting system • Start switch • Starter relay • Starter motor YPVS • YPVS unit Charging system • Lighting coil • Rectifier/regulator • Fuses • Battery leads — • Battery Electric bilge pump •...
Page 337 Stepping motor stuck closed Stepping motor stuck open If the Yamaha Diagnostic System is not used to check the symptoms listed in the table, the error codes can be checked easily with the self-diagnosis in the multifunction meter. How-...
Page 338 GP1300R P B L È R/Y R/Y R/Y B B B B B B B B Pu/Y Pu/B Pu/R 10 11 12 W W/L B/Y B/G B/O B/L W/L O W/Y W/B 13 14 15 16 17 18 19 20 21 22 W/R L/R G/B G/R G G/Y B/R O P Pu/Y 25 26 27 28 29 30 31 32 33 34 35...
Page 339 WIRING DIAGRAM GP1300R 1 ECM Color code 2 Atmospheric pressure sensor : Black 3 YPVS servomotor : Brown 4 Spark plugs : Green 5 Ignition coils : Gray 6 Fuse (20 A) : Blue 7 Fuses (3 A) : Orange 8 Main and fuel pump relay : Pink 9 Starter relay...
Page 340 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Feb. 2003 –...

Yamaha WaveRunner GP1300R Supplementary Service Manual

General Information

Table of Contents

Specifications

Insp Adj

Table of Contents

Power Unit

Pump Chapter 6 Jet Pump Unit

Table of Contents

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Summary of Contents for Yamaha WaveRunner GP1300R